JP2016533928A - Fabrics fitted with low density polyurethane foam made using a combination of foaming and expansion methods - Google Patents
Fabrics fitted with low density polyurethane foam made using a combination of foaming and expansion methods Download PDFInfo
- Publication number
- JP2016533928A JP2016533928A JP2016536302A JP2016536302A JP2016533928A JP 2016533928 A JP2016533928 A JP 2016533928A JP 2016536302 A JP2016536302 A JP 2016536302A JP 2016536302 A JP2016536302 A JP 2016536302A JP 2016533928 A JP2016533928 A JP 2016533928A
- Authority
- JP
- Japan
- Prior art keywords
- polyurethane
- polyol
- weight
- parts
- foam
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000004744 fabric Substances 0.000 title claims abstract description 30
- 238000000034 method Methods 0.000 title claims description 37
- 238000005187 foaming Methods 0.000 title claims description 31
- 229920005830 Polyurethane Foam Polymers 0.000 title claims description 6
- 239000011496 polyurethane foam Substances 0.000 title claims description 6
- 239000000203 mixture Substances 0.000 claims abstract description 116
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 49
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 44
- 239000004814 polyurethane Substances 0.000 claims abstract description 29
- 229920002635 polyurethane Polymers 0.000 claims abstract description 29
- 230000008961 swelling Effects 0.000 claims abstract description 29
- 150000003077 polyols Chemical class 0.000 claims description 76
- 229920005862 polyol Polymers 0.000 claims description 54
- 239000006260 foam Substances 0.000 claims description 46
- 239000003054 catalyst Substances 0.000 claims description 28
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims description 24
- 229920001228 polyisocyanate Polymers 0.000 claims description 23
- 239000005056 polyisocyanate Substances 0.000 claims description 23
- 239000000945 filler Substances 0.000 claims description 22
- 239000000463 material Substances 0.000 claims description 22
- 238000002156 mixing Methods 0.000 claims description 16
- 239000000758 substrate Substances 0.000 claims description 12
- 239000004094 surface-active agent Substances 0.000 claims description 11
- 238000009835 boiling Methods 0.000 claims description 9
- 239000012948 isocyanate Substances 0.000 claims description 9
- 150000002513 isocyanates Chemical class 0.000 claims description 8
- 230000008569 process Effects 0.000 claims description 8
- 239000012298 atmosphere Substances 0.000 claims description 5
- 230000000087 stabilizing effect Effects 0.000 claims description 4
- 230000009471 action Effects 0.000 abstract description 3
- 239000010410 layer Substances 0.000 description 41
- 238000006243 chemical reaction Methods 0.000 description 15
- 230000000052 comparative effect Effects 0.000 description 14
- 238000009472 formulation Methods 0.000 description 13
- IQPQWNKOIGAROB-UHFFFAOYSA-N isocyanate group Chemical group [N-]=C=O IQPQWNKOIGAROB-UHFFFAOYSA-N 0.000 description 11
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 8
- UPMLOUAZCHDJJD-UHFFFAOYSA-N 4,4'-Diphenylmethane Diisocyanate Chemical compound C1=CC(N=C=O)=CC=C1CC1=CC=C(N=C=O)C=C1 UPMLOUAZCHDJJD-UHFFFAOYSA-N 0.000 description 7
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 description 7
- -1 beni Substances 0.000 description 7
- 229920000642 polymer Polymers 0.000 description 7
- 239000000126 substance Substances 0.000 description 7
- 239000004970 Chain extender Substances 0.000 description 6
- 230000008901 benefit Effects 0.000 description 6
- 150000001875 compounds Chemical class 0.000 description 6
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 6
- GOOHAUXETOMSMM-UHFFFAOYSA-N Propylene oxide Chemical compound CC1CO1 GOOHAUXETOMSMM-UHFFFAOYSA-N 0.000 description 5
- 239000000835 fiber Substances 0.000 description 5
- 229920000570 polyether Polymers 0.000 description 5
- 230000003068 static effect Effects 0.000 description 5
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- 239000004721 Polyphenylene oxide Substances 0.000 description 4
- 235000016976 Quercus macrolepis Nutrition 0.000 description 4
- 244000305267 Quercus macrolepis Species 0.000 description 4
- 229910000019 calcium carbonate Inorganic materials 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 229920005903 polyol mixture Polymers 0.000 description 4
- 239000011541 reaction mixture Substances 0.000 description 4
- 238000011144 upstream manufacturing Methods 0.000 description 4
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- SJRJJKPEHAURKC-UHFFFAOYSA-N N-Methylmorpholine Chemical compound CN1CCOCC1 SJRJJKPEHAURKC-UHFFFAOYSA-N 0.000 description 3
- 229920000538 Poly[(phenyl isocyanate)-co-formaldehyde] Polymers 0.000 description 3
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 3
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 3
- 229920001400 block copolymer Polymers 0.000 description 3
- 230000003111 delayed effect Effects 0.000 description 3
- JJPZOIJCDNHCJP-UHFFFAOYSA-N dibutyl(sulfanylidene)tin Chemical compound CCCC[Sn](=S)CCCC JJPZOIJCDNHCJP-UHFFFAOYSA-N 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- MSSNHSVIGIHOJA-UHFFFAOYSA-N pentafluoropropane Chemical compound FC(F)CC(F)(F)F MSSNHSVIGIHOJA-UHFFFAOYSA-N 0.000 description 3
- 229920000728 polyester Polymers 0.000 description 3
- 229920005906 polyester polyol Polymers 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- 229920005604 random copolymer Polymers 0.000 description 3
- DVKJHBMWWAPEIU-UHFFFAOYSA-N toluene 2,4-diisocyanate Chemical compound CC1=CC=C(N=C=O)C=C1N=C=O DVKJHBMWWAPEIU-UHFFFAOYSA-N 0.000 description 3
- LFSYUSUFCBOHGU-UHFFFAOYSA-N 1-isocyanato-2-[(4-isocyanatophenyl)methyl]benzene Chemical compound C1=CC(N=C=O)=CC=C1CC1=CC=CC=C1N=C=O LFSYUSUFCBOHGU-UHFFFAOYSA-N 0.000 description 2
- 240000000491 Corchorus aestuans Species 0.000 description 2
- 235000011777 Corchorus aestuans Nutrition 0.000 description 2
- 235000010862 Corchorus capsularis Nutrition 0.000 description 2
- 229920000742 Cotton Polymers 0.000 description 2
- 239000004971 Cross linker Substances 0.000 description 2
- OAKJQQAXSVQMHS-UHFFFAOYSA-N Hydrazine Chemical compound NN OAKJQQAXSVQMHS-UHFFFAOYSA-N 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 2
- GLUUGHFHXGJENI-UHFFFAOYSA-N Piperazine Chemical compound C1CNCCN1 GLUUGHFHXGJENI-UHFFFAOYSA-N 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- ADCOVFLJGNWWNZ-UHFFFAOYSA-N antimony trioxide Chemical compound O=[Sb]O[Sb]=O ADCOVFLJGNWWNZ-UHFFFAOYSA-N 0.000 description 2
- WERYXYBDKMZEQL-UHFFFAOYSA-N butane-1,4-diol Chemical compound OCCCCO WERYXYBDKMZEQL-UHFFFAOYSA-N 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
- 229910002092 carbon dioxide Inorganic materials 0.000 description 2
- 210000004027 cell Anatomy 0.000 description 2
- 210000003850 cellular structure Anatomy 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 239000006071 cream Substances 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 229930195733 hydrocarbon Natural products 0.000 description 2
- 150000002430 hydrocarbons Chemical class 0.000 description 2
- 229920001778 nylon Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 239000000454 talc Substances 0.000 description 2
- 229910052623 talc Inorganic materials 0.000 description 2
- 150000003512 tertiary amines Chemical class 0.000 description 2
- 239000004753 textile Substances 0.000 description 2
- RUELTTOHQODFPA-UHFFFAOYSA-N toluene 2,6-diisocyanate Chemical compound CC1=C(N=C=O)C=CC=C1N=C=O RUELTTOHQODFPA-UHFFFAOYSA-N 0.000 description 2
- IMNIMPAHZVJRPE-UHFFFAOYSA-N triethylenediamine Chemical compound C1CN2CCN1CC2 IMNIMPAHZVJRPE-UHFFFAOYSA-N 0.000 description 2
- 210000002268 wool Anatomy 0.000 description 2
- 239000002759 woven fabric Substances 0.000 description 2
- DNIAPMSPPWPWGF-VKHMYHEASA-N (+)-propylene glycol Chemical compound C[C@H](O)CO DNIAPMSPPWPWGF-VKHMYHEASA-N 0.000 description 1
- SHWZFQPXYGHRKT-FDGPNNRMSA-N (z)-4-hydroxypent-3-en-2-one;nickel Chemical compound [Ni].C\C(O)=C\C(C)=O.C\C(O)=C\C(C)=O SHWZFQPXYGHRKT-FDGPNNRMSA-N 0.000 description 1
- VGHSXKTVMPXHNG-UHFFFAOYSA-N 1,3-diisocyanatobenzene Chemical compound O=C=NC1=CC=CC(N=C=O)=C1 VGHSXKTVMPXHNG-UHFFFAOYSA-N 0.000 description 1
- YPFDHNVEDLHUCE-UHFFFAOYSA-N 1,3-propanediol Substances OCCCO YPFDHNVEDLHUCE-UHFFFAOYSA-N 0.000 description 1
- CDMDQYCEEKCBGR-UHFFFAOYSA-N 1,4-diisocyanatocyclohexane Chemical compound O=C=NC1CCC(N=C=O)CC1 CDMDQYCEEKCBGR-UHFFFAOYSA-N 0.000 description 1
- DTZHXCBUWSTOPO-UHFFFAOYSA-N 1-isocyanato-4-[(4-isocyanato-3-methylphenyl)methyl]-2-methylbenzene Chemical compound C1=C(N=C=O)C(C)=CC(CC=2C=C(C)C(N=C=O)=CC=2)=C1 DTZHXCBUWSTOPO-UHFFFAOYSA-N 0.000 description 1
- PISLZQACAJMAIO-UHFFFAOYSA-N 2,4-diethyl-6-methylbenzene-1,3-diamine Chemical compound CCC1=CC(C)=C(N)C(CC)=C1N PISLZQACAJMAIO-UHFFFAOYSA-N 0.000 description 1
- VZDIRINETBAVAV-UHFFFAOYSA-N 2,4-diisocyanato-1-methylcyclohexane Chemical compound CC1CCC(N=C=O)CC1N=C=O VZDIRINETBAVAV-UHFFFAOYSA-N 0.000 description 1
- KRZTYSCUOUIFHR-BDAKNGLRSA-N 2-[(1r,3s)-2,2-dimethyl-3-(2-oxopropyl)cyclopropyl]acetonitrile Chemical group CC(=O)C[C@H]1[C@@H](CC#N)C1(C)C KRZTYSCUOUIFHR-BDAKNGLRSA-N 0.000 description 1
- LCZVSXRMYJUNFX-UHFFFAOYSA-N 2-[2-(2-hydroxypropoxy)propoxy]propan-1-ol Chemical compound CC(O)COC(C)COC(C)CO LCZVSXRMYJUNFX-UHFFFAOYSA-N 0.000 description 1
- JOMNTHCQHJPVAZ-UHFFFAOYSA-N 2-methylpiperazine Chemical compound CC1CNCCN1 JOMNTHCQHJPVAZ-UHFFFAOYSA-N 0.000 description 1
- RNLHGQLZWXBQNY-UHFFFAOYSA-N 3-(aminomethyl)-3,5,5-trimethylcyclohexan-1-amine Chemical compound CC1(C)CC(N)CC(C)(CN)C1 RNLHGQLZWXBQNY-UHFFFAOYSA-N 0.000 description 1
- ZPIFKCVYZBVZIV-UHFFFAOYSA-N 3-chloro-1,1,1-trifluoropropane Chemical compound FC(F)(F)CCCl ZPIFKCVYZBVZIV-UHFFFAOYSA-N 0.000 description 1
- FJSUFIIJYXMJQO-UHFFFAOYSA-N 3-methylpentane-1,5-diamine Chemical compound NCCC(C)CCN FJSUFIIJYXMJQO-UHFFFAOYSA-N 0.000 description 1
- ZRWNRAJCPNLYAK-UHFFFAOYSA-N 4-bromobenzamide Chemical compound NC(=O)C1=CC=C(Br)C=C1 ZRWNRAJCPNLYAK-UHFFFAOYSA-N 0.000 description 1
- RZBBHEJLECUBJT-UHFFFAOYSA-N 6-methylheptyl 2-sulfanylacetate Chemical compound CC(C)CCCCCOC(=O)CS RZBBHEJLECUBJT-UHFFFAOYSA-N 0.000 description 1
- 229920002972 Acrylic fiber Polymers 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 229910052582 BN Inorganic materials 0.000 description 1
- 239000004604 Blowing Agent Substances 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 239000009261 D 400 Substances 0.000 description 1
- PIICEJLVQHRZGT-UHFFFAOYSA-N Ethylenediamine Chemical compound NCCN PIICEJLVQHRZGT-UHFFFAOYSA-N 0.000 description 1
- 241000408710 Hansa Species 0.000 description 1
- 241000238631 Hexapoda Species 0.000 description 1
- SPTUBPSDCZNVSI-UHFFFAOYSA-N N=C=O.N=C=O.COC1=CC=CC=C1C1=CC=CC=C1OC Chemical compound N=C=O.N=C=O.COC1=CC=CC=C1C1=CC=CC=C1OC SPTUBPSDCZNVSI-UHFFFAOYSA-N 0.000 description 1
- CBENFWSGALASAD-UHFFFAOYSA-N Ozone Chemical compound [O-][O+]=O CBENFWSGALASAD-UHFFFAOYSA-N 0.000 description 1
- 229920003171 Poly (ethylene oxide) Polymers 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 229920002323 Silicone foam Polymers 0.000 description 1
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 1
- ISKQADXMHQSTHK-UHFFFAOYSA-N [4-(aminomethyl)phenyl]methanamine Chemical compound NCC1=CC=C(CN)C=C1 ISKQADXMHQSTHK-UHFFFAOYSA-N 0.000 description 1
- YIMQCDZDWXUDCA-UHFFFAOYSA-N [4-(hydroxymethyl)cyclohexyl]methanol Chemical compound OCC1CCC(CO)CC1 YIMQCDZDWXUDCA-UHFFFAOYSA-N 0.000 description 1
- UKLDJPRMSDWDSL-UHFFFAOYSA-L [dibutyl(dodecanoyloxy)stannyl] dodecanoate Chemical compound CCCCCCCCCCCC(=O)O[Sn](CCCC)(CCCC)OC(=O)CCCCCCCCCCC UKLDJPRMSDWDSL-UHFFFAOYSA-L 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 125000002723 alicyclic group Chemical group 0.000 description 1
- 125000002947 alkylene group Chemical group 0.000 description 1
- RREGISFBPQOLTM-UHFFFAOYSA-N alumane;trihydrate Chemical compound O.O.O.[AlH3] RREGISFBPQOLTM-UHFFFAOYSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 150000001412 amines Chemical group 0.000 description 1
- IMUDHTPIFIBORV-UHFFFAOYSA-N aminoethylpiperazine Chemical compound NCCN1CCNCC1 IMUDHTPIFIBORV-UHFFFAOYSA-N 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920003235 aromatic polyamide Polymers 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- 239000010426 asphalt Substances 0.000 description 1
- 239000010428 baryte Substances 0.000 description 1
- 229910052601 baryte Inorganic materials 0.000 description 1
- 239000000440 bentonite Substances 0.000 description 1
- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- 230000001588 bifunctional effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052797 bismuth Inorganic materials 0.000 description 1
- 230000005587 bubbling Effects 0.000 description 1
- 239000004202 carbamide Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000004359 castor oil Substances 0.000 description 1
- 235000019438 castor oil Nutrition 0.000 description 1
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- 238000010960 commercial process Methods 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
- XLJMAIOERFSOGZ-UHFFFAOYSA-M cyanate Chemical compound [O-]C#N XLJMAIOERFSOGZ-UHFFFAOYSA-M 0.000 description 1
- 150000001983 dialkylethers Chemical class 0.000 description 1
- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 description 1
- WCRDXYSYPCEIAK-UHFFFAOYSA-N dibutylstannane Chemical compound CCCC[SnH2]CCCC WCRDXYSYPCEIAK-UHFFFAOYSA-N 0.000 description 1
- 239000012975 dibutyltin dilaurate Substances 0.000 description 1
- RFAIKXASDCRKEP-UHFFFAOYSA-N dioctyl(sulfanylidene)tin Chemical compound CCCCCCCC[Sn](=S)CCCCCCCC RFAIKXASDCRKEP-UHFFFAOYSA-N 0.000 description 1
- SZXQTJUDPRGNJN-UHFFFAOYSA-N dipropylene glycol Chemical compound OCCCOCCCO SZXQTJUDPRGNJN-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000000284 extract Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- NBVXSUQYWXRMNV-UHFFFAOYSA-N fluoromethane Chemical compound FC NBVXSUQYWXRMNV-UHFFFAOYSA-N 0.000 description 1
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- 239000010438 granite Substances 0.000 description 1
- 239000005337 ground glass Substances 0.000 description 1
- 150000002366 halogen compounds Chemical class 0.000 description 1
- RRAMGCGOFNQTLD-UHFFFAOYSA-N hexamethylene diisocyanate Chemical compound O=C=NCCCCCCN=C=O RRAMGCGOFNQTLD-UHFFFAOYSA-N 0.000 description 1
- SYECJBOWSGTPLU-UHFFFAOYSA-N hexane-1,1-diamine Chemical compound CCCCCC(N)N SYECJBOWSGTPLU-UHFFFAOYSA-N 0.000 description 1
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- 239000012943 hotmelt Substances 0.000 description 1
- 125000004029 hydroxymethyl group Chemical group [H]OC([H])([H])* 0.000 description 1
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- LZKLAOYSENRNKR-LNTINUHCSA-N iron;(z)-4-oxoniumylidenepent-2-en-2-olate Chemical compound [Fe].C\C(O)=C\C(C)=O.C\C(O)=C\C(C)=O.C\C(O)=C\C(C)=O LZKLAOYSENRNKR-LNTINUHCSA-N 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 239000004816 latex Substances 0.000 description 1
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- DSSXKBBEJCDMBT-UHFFFAOYSA-M lead(2+);octanoate Chemical compound [Pb+2].CCCCCCCC([O-])=O DSSXKBBEJCDMBT-UHFFFAOYSA-M 0.000 description 1
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- 229910052901 montmorillonite Inorganic materials 0.000 description 1
- 150000002902 organometallic compounds Chemical class 0.000 description 1
- 125000002524 organometallic group Chemical group 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
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- 229920000058 polyacrylate Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920006254 polymer film Polymers 0.000 description 1
- 239000002685 polymerization catalyst Substances 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920000166 polytrimethylene carbonate Polymers 0.000 description 1
- 238000010944 pre-mature reactiony Methods 0.000 description 1
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- 230000009257 reactivity Effects 0.000 description 1
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- 150000003335 secondary amines Chemical group 0.000 description 1
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- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000013514 silicone foam Substances 0.000 description 1
- 239000012970 tertiary amine catalyst Substances 0.000 description 1
- SYRHIZPPCHMRIT-UHFFFAOYSA-N tin(4+) Chemical compound [Sn+4] SYRHIZPPCHMRIT-UHFFFAOYSA-N 0.000 description 1
- KSBAEPSJVUENNK-UHFFFAOYSA-L tin(ii) 2-ethylhexanoate Chemical compound [Sn+2].CCCCC(CC)C([O-])=O.CCCCC(CC)C([O-])=O KSBAEPSJVUENNK-UHFFFAOYSA-L 0.000 description 1
- AFNRRBXCCXDRPS-UHFFFAOYSA-N tin(ii) sulfide Chemical compound [Sn]=S AFNRRBXCCXDRPS-UHFFFAOYSA-N 0.000 description 1
- 230000032258 transport Effects 0.000 description 1
- ZIBGPFATKBEMQZ-UHFFFAOYSA-N triethylene glycol Chemical compound OCCOCCOCCO ZIBGPFATKBEMQZ-UHFFFAOYSA-N 0.000 description 1
- 238000010792 warming Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0043—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers
- D06N3/0047—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers obtained by incorporating air, i.e. froth
-
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Abstract
ポリウレタンクッションが裏打ちされた織物は、発泡ポリウレタン形成混合物の層を織物の表面に適用することによって生産される。この混合物は、水及び物理的膨張剤の両方を含有する。層が、水及び物理的膨張剤の作用により拡張し、硬化して、176g/L以下の密度を有する取り付けられたクッションを形成する。【選択図】なしFabrics lined with polyurethane cushions are produced by applying a layer of foamed polyurethane-forming mixture to the surface of the fabric. This mixture contains both water and a physical swelling agent. The layer expands and cures by the action of water and a physical swelling agent to form an attached cushion having a density of 176 g / L or less. [Selection figure] None
Description
本発明は、低密度発泡ポリウレタン裏地を有する織物、及びそのような織物を作製する方法に関する。 The present invention relates to a fabric having a low density foamed polyurethane backing and a method of making such a fabric.
取り付けられたポリウレタンクッションが裏打ちされたカーペットは、長年市販されている。これらのカーペットを作製するための方法は、例えば、米国特許第4,296,159号、同第4,336,089号、同第4,405,393号、同第4,483,894号、同第4,853,054号、同第4,853,280号、同第5,104,693号、同第5,646,195号、同第6,372,810号、及び同第6,790,872号に記載されている。 Carpets lined with attached polyurethane cushions have been on the market for many years. Methods for making these carpets include, for example, U.S. Pat. Nos. 4,296,159, 4,336,089, 4,405,393, 4,483,894, 4,853,054, 4,853,280, 5,104,693, 5,646,195, 6,372,810, and 6, 790,872.
取り付けられたクッションは、ポリウレタン形成組成物をカーペットの裏面に適用し、該組成物が定位置に硬化するのを可能にすることによって調製される。ガスを安定化したポリウレタン形成組成物に組み込むことによって気泡構造が作り出される。 The attached cushion is prepared by applying a polyurethane-forming composition to the backside of the carpet and allowing the composition to cure in place. A cellular structure is created by incorporating gas into the stabilized polyurethane-forming composition.
ポリウレタンフォーム製造プロセスの大部分において、気泡構造は、化学膨張剤及び/または物理的膨張剤をポリウレタンフォーム配合物に組み込むことによって付与される。化学膨張剤は、硬化反応の条件下で反応して、ガスを発生させる。最も一般的に使用される化学膨張剤は、水であり、ガス(二酸化炭素)を発生することに加えて、イソシアネート基と反応して、ポリマー鎖を伸長する尿素結合をもたらす。物理的膨張剤は、硬化条件下で揮発して膨張ガスを形成する、低沸点の液体である。様々な種類の炭化水素、フッ化炭素、ヒドロフルオロカーボン、及び他のハロゲン化合物が使用されている。 In most of the polyurethane foam manufacturing processes, the cellular structure is imparted by incorporating chemical and / or physical expansion agents into the polyurethane foam formulation. The chemical expansion agent reacts under the conditions of the curing reaction to generate gas. The most commonly used chemical expansion agent is water, in addition to generating gas (carbon dioxide), it reacts with isocyanate groups to give urea linkages that extend the polymer chain. A physical swelling agent is a low boiling liquid that volatilizes under curing conditions to form an expanding gas. Various types of hydrocarbons, fluorocarbons, hydrofluorocarbons, and other halogen compounds are used.
膨張系が織物裏打ち用途(例えば、米国特許第4,405,393号及び同第4,312,817号を参照のこと)に試みられているが、製造プロセスは、これらの系の使用には適していない。これにおける理由は、ポリウレタン配合物が、分与され、織物表面上に広げられ、既定の厚さに計量されなければならないためである。これらの作業を行うには、ある程度の時間を要する。化学的膨張系は、迅速に反応しすぎて、これらの作業に適応しない。それらは、とても迅速に分子量及び粘度が上昇するため、特別な器具を用いて、困難を伴いながら広げ、計量することができるのみである。別の問題は、適用したクッションが、通常非常に薄く、そのため、非常に高い表面積を有することである。ポリウレタン配合物が硬化する際に、膨張剤が大量のガスを形成する場合、ガスは、硬化混合物の露出面を通して漏出する傾向があり、これにより、膨張効率の大きな損失をもたらす。同様の考慮は、織物裏打ちプロセスにおける物理的膨張剤の使用を本質的に妨げてきた。物理的膨張剤の揮発は、高温を必要とし、構成成分を加熱するか、または硬化反応の発熱によって達成され得る。しかしながら、温度の上昇はまた、硬化速度も増加させ、そのため、粘性がありすぎて制御することができなくなる前に、泡沫配合物を適用し、計量する際にも困難に直面する。実際には、プロセスの残りのステップに対する膨張の順番付けは、商業的規模において管理するのが困難である。 Although expansion systems have been attempted for textile backing applications (see, for example, US Pat. Nos. 4,405,393 and 4,312,817), the manufacturing process is not suitable for use with these systems. Not suitable. The reason for this is that the polyurethane formulation must be dispensed, spread over the fabric surface and metered to a predetermined thickness. A certain amount of time is required to perform these operations. Chemical expansion systems react too quickly and are not suitable for these tasks. They increase in molecular weight and viscosity so quickly that they can only be spread and metered with difficulty using special equipment. Another problem is that the applied cushion is usually very thin and therefore has a very high surface area. As the polyurethane formulation cures, if the expansion agent forms a large amount of gas, the gas tends to escape through the exposed surface of the cured mixture, thereby resulting in a significant loss of expansion efficiency. Similar considerations have essentially prevented the use of physical swelling agents in the textile backing process. The volatilization of the physical swelling agent requires high temperatures and can be accomplished by heating the components or by exotherm of the curing reaction. However, increasing the temperature also increases the cure rate, so it is also difficult to apply and meter the foam formulation before it is too viscous to be controlled. In practice, the expansion ordering for the remaining steps of the process is difficult to manage on a commercial scale.
これらの理由により、商業的プロセスは、ほとんど均一に発泡ポリウレタン系を使用する。配合物を織物に適用する前に、ガスを泡沫配合物中へ泡立てる。硬化反応時にガスを発生させる必要がないため、膨張及び硬化プロセスを順番付ける問題が排除される。このことは、これらの系が配合されるのを可能にし、そのため、それらは最初に混合されるときにゆっくりと反応する。遅い初期硬化は、配合物が混合され、分注され、カーペットの裏面に均一に適用し、計量するのに十分な時間を許容する。計量された泡沫配合物は、その後、それを高温に曝露することによって、比較的迅速に硬化される。 For these reasons, commercial processes use foamed polyurethane systems almost uniformly. Before applying the formulation to the fabric, gas is bubbled into the foam formulation. Since no gas needs to be generated during the curing reaction, the problem of sequencing the expansion and curing process is eliminated. This allows these systems to be formulated so that they react slowly when first mixed. Slow initial cure allows sufficient time for the formulation to be mixed, dispensed, applied evenly to the backside of the carpet and metered. The weighed foam formulation is then cured relatively quickly by exposing it to high temperatures.
発泡系による問題は、硬化ポリウレタンフォームにおいて11〜12ポンド/立方フィート未満の密度をもたらすのが困難であることである。ある特定の製品に対する性能要求が、あまり厳しくない、または単に費用を削減するのみであり得るため、より柔軟な手触りを得るためにある特定のカーペット製品においては、より低い泡沫密度が所望される。より低密度の発泡ポリウレタンカーペット裏打ちを生産することができないことで、取り付けられたポリウレタンクッションを有して生産されたカーペット製品の範囲は限定されてきた。 The problem with foam systems is that it is difficult to produce densities of less than 11-12 pounds / cubic foot in cured polyurethane foam. A lower foam density is desired in certain carpet products to obtain a softer feel because the performance requirements for a particular product may be less stringent or simply reduce costs. The inability to produce lower density foamed polyurethane carpet backings has limited the range of carpet products produced with attached polyurethane cushions.
場合によっては、水が、発泡ポリウレタンカーペット裏打ち配合物に組み込まれてきた。この実施の例は、例えば、米国特許第4,853,280号、同第6,372,810号、及び同第6,790,872号に記載されている。米国特許第4,853,280号に記載される方法において、取り付けられたポリウレタンクッションは発泡系から調製され、これに、約0.1重量%の水(未充填系を基準にして〜0.2%)が添加される。結果として生じるクッションの密度は、11ポンド/立方フィートとして報告されている。米国特許第6,372,810号において、約10倍高いレベルの水が、発泡泡沫配合物に組み込まれる。しかしながら、結果として生じる取り付けられたクッションの密度は、依然として、12ポンド/立方フィート超として報告されている。米国特許第6,372,810号の例に報告されるより高い充填剤レベルを考慮に入れたとしても、追加の水は、泡密度のさらなる減少をもたらさない。同様に、高いクッション密度が、米国特許第6,790,872号に報告されている。 In some cases, water has been incorporated into foamed polyurethane carpet backing formulations. Examples of this implementation are described, for example, in U.S. Pat. Nos. 4,853,280, 6,372,810, and 6,790,872. In the method described in U.S. Pat. No. 4,853,280, an attached polyurethane cushion is prepared from a foamed system, to which is added about 0.1% by weight of water (.about.0. 2%) is added. The resulting cushion density is reported as 11 pounds / cubic foot. In US Pat. No. 6,372,810, about 10 times higher levels of water are incorporated into foam foam formulations. However, the resulting installed cushion density is still reported as over 12 pounds / cubic foot. Even taking into account the higher filler levels reported in the example of US Pat. No. 6,372,810, the additional water does not result in a further reduction in foam density. Similarly, high cushion density is reported in US Pat. No. 6,790,872.
米国特許出願公開第2007−0197674号は、低密度(10ポンド/立方フィート(160g/L)未満)の取り付けられたクッションが織物に適用され得る手法を記載している。発泡剤及び化学的膨張剤の混合物が使用される。閉じ込め層を、適用され、計量された泡沫配合物の露出面に適用して、膨張するガスが漏出するのを防止し、10ポンド/立方フィート(160g/L)未満の泡沫密度を得ることができる。この方法は、商業的成功を見出した。しかしながら、閉じ込め層を必要とし、材料費用がかさみ、さらなる装備を必要とし、操業費用を増加させ、この方法にさらなる複雑性を導入する。さらに、水/イソシアネートの反応を触媒するためには、より高い触媒レベルが必要となり、同様に、硬化反応を加速し、開放時間を削減し、配合物に適用し、計量することをより困難にする。水の使用はまた、場合によっては所望されるよりも堅く、硬質な泡沫を生成する。 US Patent Publication No. 2007-0197674 describes a technique in which a low density (less than 10 pounds / cubic foot (160 g / L)) attached cushion can be applied to a fabric. A mixture of blowing agent and chemical swelling agent is used. A confinement layer may be applied to the exposed surface of the applied and metered foam formulation to prevent leakage of the expanding gas and obtain a foam density of less than 10 pounds / cubic foot (160 g / L). it can. This method has found commercial success. However, it requires a confinement layer, increases material costs, requires additional equipment, increases operating costs, and introduces additional complexity to the method. In addition, higher catalyst levels are required to catalyze the water / isocyanate reaction, as well as accelerating the curing reaction, reducing open time, making it more difficult to apply and meter into the formulation. To do. The use of water also produces foams that are stiffer and harder than desired.
それ故に、閉じ込め層を必要とせず、より低密度の取り付けられたポリウレタンクッションがカーペットまたは他の織物に適用され得る、実用的で容易に制御可能な方法は、この業界において未だ満たされない必要性である。 Therefore, a practical and easily controllable method that does not require a containment layer and a lower density attached polyurethane cushion can be applied to carpets or other fabrics is an unmet need in the industry. is there.
本発明は、クッションが裏打ちされた織物を作製するための方法であって、
a)1リットル当たり約250〜600グラムの密度を有する発泡ポリウレタン形成組成物であって、該ポリウレタン形成組成物が、少なくとも400のヒドロキシル当量を有する少なくとも1つのポリオールを含む1つ以上のポリオール、少なくとも400のヒドロキシル当量を有するポリオール(複数可)100重量部当たり0.25〜2部の水、少なくとも400のヒドロキシル当量を有するポリオール(複数可)100重量部当たり3〜10重量部の、−30〜40℃の沸点を有する物理的膨張剤、少なくとも400のヒドロキシル当量を有するポリオール(複数可)100重量部当たり100〜400重量部の充填剤、泡沫安定化界面活性剤、85〜130のイソシアネート指数を提供するのに十分な量の少なくとも1つのポリイソシアネート、及び該ポリウレタン形成組成物が少なくとも180秒のゲル化時間を有するような量のポリウレタン触媒を含む、発泡ポリウレタン形成組成物を形成することと、
b)少なくとも24インチ(61cm)の幅を有する織物の上面をわたる0.05〜0.75インチ(0.127〜1.9cm)の厚さの層へと未硬化の泡を形成することと、
c)発泡組成物が自由に上昇して、織物に結合された176グラム/リットル(11ポンド/立方フィート)以下の密度を有する発泡ポリウレタンクッションを形成することができるように、発泡組成物の層を、その上面が大気に開放された状態で硬化させることと、を含む。
The present invention is a method for making a fabric lined with a cushion, comprising:
a) a foamed polyurethane-forming composition having a density of about 250-600 grams per liter, wherein the polyurethane-forming composition comprises at least one polyol having a hydroxyl equivalent weight of at least 400, at least 0.25-2 parts water per 100 parts by weight of polyol (s) having a hydroxyl equivalent of 400, 3-10 parts by weight per 100 parts by weight of polyol (s) having a hydroxyl equivalent of 400, -30 A physical swelling agent having a boiling point of 40 ° C., 100 to 400 parts by weight of filler, 100 parts by weight of a polyol (s) having a hydroxyl equivalent weight of at least 400, a foam stabilizing surfactant, an isocyanate index of 85 to 130 At least one polyi in an amount sufficient to provide And the cyanate, and the polyurethane-forming composition comprises an amount of polyurethane catalyst such as those having a gelling time of at least 180 seconds, to form a polyurethane foam forming composition,
b) forming uncured foam into a 0.05 to 0.75 inch (0.127 to 1.9 cm) thick layer over the top surface of the fabric having a width of at least 24 inches (61 cm); ,
c) A layer of foam composition so that the foam composition can rise freely to form a foam polyurethane cushion having a density of 176 grams / liter (11 pounds / cubic foot) or less bonded to the fabric. Is cured with its upper surface open to the atmosphere.
本発明の方法は、良質で低密度ポリウレタンクッションがカーペット等の織物に取り付けることを可能にする。176グラム/リットル以下、多くの場合、160グラム/リットル以下の密度を有する取り付けられたクッションは、商業的規模の実装に有用である方法において容易に調製される。驚くべきことに、米国特許出願公開第2007−0197674号の方法において必要とされるような閉じ込め層は、必要とされない。硬化された泡沫は、米国特許出願公開第2007−0197674号の方法において形成されるものよりも柔らかい傾向があり、そのため、より良好なクッション性、弾力、及び手触りを提供する。 The method of the present invention allows a good quality, low density polyurethane cushion to be attached to a fabric such as a carpet. Attached cushions having a density of 176 grams / liter or less, and often 160 grams / liter or less, are readily prepared in a manner that is useful for commercial scale implementations. Surprisingly, a confinement layer as required in the method of US 2007-0197674 is not required. Cured foam tends to be softer than that formed in the method of US Patent Application Publication No. 2007-0197674, thus providing better cushioning, elasticity, and feel.
本発明の方法は、ポリウレタン形成組成物が発泡され、化学的に膨張し(水とイソシアネート基との反応によって)、物理的に膨張する(物理的膨張剤の揮発によって)ことを特徴とする。発泡自体が使用される場合とは異なり、176グラム/リットル以下のクッション密度が本発明により容易に得られる。発泡及び化学的膨張が組み合わせて使用される場合(米国特許出願公開第2007−0197674号等の場合)とは異なり、本発明は、閉じ込め層を必要としない、低密度の取り付けられたクッションを提供する。米国特許出願公開第2007−0197674号に記載される方法にわたる本発明のさらなる利点は、ポリウレタン反応がよりゆっくりと進行する傾向にあり、泡を基板に適用し、それを層に形成するためのより多くの時間を提供することである。 The process of the invention is characterized in that the polyurethane-forming composition is foamed, chemically expanded (by reaction of water with isocyanate groups) and physically expanded (by volatilization of the physical expansion agent). Unlike the case where foaming itself is used, a cushion density of 176 grams / liter or less is easily obtained by the present invention. Unlike when foaming and chemical expansion are used in combination (such as in US 2007-0197674), the present invention provides a low density attached cushion that does not require a confinement layer To do. A further advantage of the present invention over the method described in U.S. Patent Application Publication No. 2007-0197674 is that the polyurethane reaction tends to proceed more slowly, more than applying foam to a substrate and forming it into a layer. Is to provide a lot of time.
米国特許出願公開第2007−0197674号の方法と比較した別の利点は、物理的膨張剤がポリウレタン形成組成物の粘度を軽減する(同等レベルの充填剤で)ことである。これは、依然として加工粘度を維持しつつ、より低い動作圧力を使用することを可能にするか、またはより高いレベルの充填剤を本組成物に組み込むことを可能にする。充填剤の量の増加は、重大な経済上の利点を提供することができる。さらなる別の利点は、このクッションがより柔軟になる傾向があり、これはより良好なクッション性を提供する。 Another advantage compared to the method of US 2007-0197674 is that the physical expansion agent reduces the viscosity of the polyurethane-forming composition (with an equivalent level of filler). This allows a lower operating pressure to be used while still maintaining the processing viscosity, or allows higher levels of filler to be incorporated into the composition. Increasing the amount of filler can provide significant economic benefits. Yet another advantage is that this cushion tends to be more flexible, which provides better cushioning.
発泡ポリウレタン形成組成物は、この方法のステップa)において形成される。ポリウレタン形成組成物は、少なくとも1つのポリオール、水、−30〜40℃の沸点を有する液体物理的膨張剤、充填剤粒子、フォームを安定化する界面活性剤、少なくとも1つのポリイソシアネート、及びポリウレタン触媒を含有する。ポリウレタン形成組成物に提供されるこれらの構成成分の相対量は、以下により十分に記載されている。 A foamed polyurethane-forming composition is formed in step a) of the process. The polyurethane-forming composition comprises at least one polyol, water, a liquid physical expansion agent having a boiling point of −30 to 40 ° C., filler particles, a surfactant that stabilizes the foam, at least one polyisocyanate, and a polyurethane catalyst. Containing. The relative amounts of these components provided in the polyurethane-forming composition are more fully described below.
これらの材料の混合する順序は、一般に、重要な意味を持たないが、但し、水及び物理的膨張剤の作用により、組成物が十分に膨張する前に、組成物を発泡させ、織物上の層に形成することとする。しかしながら、ある特定の混合順序は、利点があり、したがって好ましい。概して、ポリオールを水、物理的膨張剤、及びポリイソシアネートと混合する前に、充填剤をポリオールと混合することが好ましい。したがって、好ましい方法において、ポリオール及び充填剤がブレンドされ、続いて、これらの他の材料が添加される。 The order in which these materials are mixed is generally not critical, except that the composition is allowed to foam before the composition fully expands due to the action of water and physical swelling agents on the fabric. It shall be formed in a layer. However, certain mixing orders have advantages and are therefore preferred. In general, it is preferred to mix the filler with the polyol before mixing the polyol with water, the physical swelling agent, and the polyisocyanate. Thus, in a preferred method, the polyol and filler are blended, followed by the addition of these other materials.
界面活性剤は、いつでも適宜に添加されるが、好ましくは、ポリイソシアネートより前、または同時にポリオールに添加される。 The surfactant is appropriately added at any time, but is preferably added to the polyol before or simultaneously with the polyisocyanate.
ポリイソシアネートは、発泡ステップ直前に、ポリオール/充填剤の混合物に添加されるのが好ましい。 The polyisocyanate is preferably added to the polyol / filler mixture just prior to the foaming step.
ポリオールをポリイソシアネート、界面活性剤、触媒、及び他の構成成分と混合する前に、水を(典型的には、ポリオールを充填剤と混合した後に)ポリオールに混合してもよい。しかしながら、発泡ステップの直前、それと同時に、またはあまり好ましくないが、発泡ステップが完了した後に、充填したポリオール、ポリイソシアネート、及び界面活性剤の混合物に水を導入することが好ましい。水とイソシアネートとの反応は、ポリオールとイソシアネート基との反応よりも迅速に起こりやすいため、水添加の遅れは、初期硬化を遅らせ、さらなる開放時間を提供するという利点がある。 Before mixing the polyol with the polyisocyanate, surfactant, catalyst, and other components, water may be mixed with the polyol (typically after mixing the polyol with the filler). However, it is preferred to introduce water into the charged polyol, polyisocyanate, and surfactant mixture immediately before, simultaneously with, or less preferred, after the foaming step is complete. Since the reaction of water with isocyanate is more likely to occur more quickly than the reaction of polyol with isocyanate groups, the delay in water addition has the advantage of delaying the initial cure and providing additional open time.
水は、担体ポリオールとのブレンドとして適宜添加される。そのようなブレンドは、しばしば、混合するのが容易であり、体積が大きいほど、正確に計測するのが容易になり得るため、(水の体積のみと比較して)ポリオール/水のブレンドの粘度が高いほど、他の構成成分に混合するのを容易にする。さらに、水が高い溶解度を有するポリオールを選択することは、水の混和性を増加させ、反応混合物により密接に水を分散させるのに役立つと考えられている。これは、微細で不均一なセルを生成するのに役立ち、製品耐久性及び静的荷重回復を向上し得る。そのような担体ポリオールは、好適には、ポリオール100重量部当たり少なくとも30、特に少なくとも40重量部の水が、室温(〜22℃)で溶解できるものである。担体ポリオール及び水の混合物は、好適には、5〜30重量%の水、特に20〜30重量%の水を含有する。好ましい担体ポリオールは、エチレンオキシドの液体(22℃で)ホモポリマー、エチレンオキシドのランダムまたはブロックコポリマー、及び少なくとも1つの他のアルキレンオキシドを含み、少なくとも10重量%、より好ましくは、少なくとも30重量%の重合エチレンオキシドを含有する。 Water is suitably added as a blend with the carrier polyol. Such blends are often easier to mix and the larger the volume, the easier it can be measured accurately, so the viscosity of the polyol / water blend (compared to the water volume alone) The higher the is, the easier it is to mix with other components. Furthermore, it is believed that selecting a polyol with high water solubility will help to increase water miscibility and disperse the water more closely in the reaction mixture. This helps to produce fine and non-uniform cells and can improve product durability and static load recovery. Such carrier polyols are preferably those in which at least 30, in particular at least 40 parts by weight of water per 100 parts by weight of polyol can be dissolved at room temperature (˜22 ° C.). The mixture of carrier polyol and water preferably contains 5 to 30% by weight of water, in particular 20 to 30% by weight of water. Preferred carrier polyols include ethylene oxide liquid (at 22 ° C.) homopolymers, random or block copolymers of ethylene oxide, and at least one other alkylene oxide, at least 10% by weight, more preferably at least 30% by weight of polymerized ethylene oxide. Containing.
物理的膨張剤は、好ましくは、ポリオール及び充填剤を混合した後に添加される。より好ましくは、物理的膨張剤は、ポリイソシアネートを添加すると同時に、またはそれを添加した後に添加される。物理的膨張剤は、発泡ステップ直前に、または発泡ステップと同時に添加され得る。発泡ステップ後に物理的膨張剤を添加することは可能であるが、物理的膨張剤を発泡混合物に配合することが困難となり得るため、あまり好ましくない。 The physical swelling agent is preferably added after mixing the polyol and filler. More preferably, the physical swelling agent is added at the same time as or after the polyisocyanate is added. The physical swelling agent can be added immediately before or simultaneously with the foaming step. Although it is possible to add a physical swelling agent after the foaming step, it is less preferred because it can be difficult to incorporate the physical swelling agent into the foaming mixture.
いくつかの実施形態において、ポリオール及び充填剤の混合物、ポリイソシアネート、及び物理的膨張剤は、発泡装置の1つ以上の上流混合デバイス中で一緒にして、一緒に混合し、発泡装置に移動される。水はまた、そのような上流混合デバイスで導入され得るか、あるいは発泡ステップ前またはそれと同時に、別々に添加され得る。 In some embodiments, the polyol and filler mixture, polyisocyanate, and physical expansion agent are combined together in one or more upstream mixing devices of the foaming device, mixed together, and transferred to the foaming device. The Water can also be introduced at such upstream mixing devices or can be added separately before or simultaneously with the foaming step.
他の実施形態において、ポリオール/充填剤の混合物は、混合デバイス中でポリイソシアネートと組み合わせられ、続いて物理的膨張剤及び水が、これもまた発泡ステップ前またはそれと同時に、添加される。 In other embodiments, the polyol / filler mixture is combined with the polyisocyanate in a mixing device, followed by addition of a physical swelling agent and water, also before or simultaneously with the foaming step.
さらに他の実施形態において、ポリオール/充填剤の混合物は、発泡装置中に別々の流れとしてこれらの構成成分を導入することによって、発泡ステップと同時にポリイソシアネート及び物理的膨張剤と組み合わせられる。これらの実施形態において、触媒及び水は、それぞれ、発泡ステップ前、発泡ステップ時、または発泡ステップ後に添加され得る。これらの実施形態において、界面活性剤は、発泡ステップより前に添加される。 In yet another embodiment, the polyol / filler mixture is combined with the polyisocyanate and physical expansion agent simultaneously with the foaming step by introducing these components as separate streams into the foaming apparatus. In these embodiments, the catalyst and water may be added before the foaming step, during the foaming step, or after the foaming step, respectively. In these embodiments, the surfactant is added prior to the foaming step.
必要に応じて、物理的膨張剤は、超大気圧下で及び/または冷却流れとして送達され、他の構成成分と混合する前に物理的膨張剤が揮発するのを防止し得る。ほとんどの場合、物理的膨張剤の少なくとも一部分が、発泡ステップ時に揮発することが予想され、そのような場合には、物理的膨張剤は、ポリウレタン形成組成物の層を適用及び計量するステップ時に継続して揮発するであろう。 If desired, the physical expansion agent may be delivered under superatmospheric pressure and / or as a cooling stream to prevent the physical expansion agent from volatilizing before mixing with other components. In most cases, at least a portion of the physical swelling agent is expected to volatilize during the foaming step, in which case the physical swelling agent continues during the step of applying and metering the layer of polyurethane-forming composition. Will volatilize.
十分な「開放時間」が基板上に発泡体を送達、分与、及び計測または計量するのに必要とされる。ゲル化の開始は、重合触媒(複数可)を以前に形成した発泡体に混合することによって遅延させ得る。触媒の添加は、水の添加と同時に、または添加後に行われるのが最も好ましい。最も好ましい実施形態において、触媒を予め発泡させた組成物に添加し、その後、水も添加し、密接に混合する。水と同様に、ほとんどの場合、触媒を、好ましくは、ブレンドとして共に添加するか、またはポリオール中で希釈して、より計測及び混合を容易にする。 Sufficient “open time” is required to deliver, dispense, and measure or meter the foam onto the substrate. The onset of gelation can be delayed by mixing the polymerization catalyst (s) with the previously formed foam. Most preferably, the catalyst is added simultaneously with or after the addition of water. In the most preferred embodiment, the catalyst is added to the prefoamed composition, followed by water and intimate mixing. As with water, in most cases, the catalyst is preferably added together as a blend or diluted in a polyol to make it easier to measure and mix.
触媒等の構成成分を、発泡ステップ後に添加する場合、構成成分をより均一に配合するために、好ましくは、静的混合デバイス(Chemineer−Kenics混合機、TAH混合機、または他の静止混合デバイス等)に製剤を流すことによって、製剤に供し、続いて混合することが好ましい。静的または静止混合機は、発泡体を著しく分解しない、または発泡体内に発泡ガスの分与しない傾向がある。 When components such as catalysts are added after the foaming step, preferably a static mixing device (such as a Chemineer-Kenix mixer, a TAH mixer, or other static mixing device, etc.) in order to blend the components more uniformly It is preferable that the preparation is supplied to the preparation by flowing the preparation into the composition followed by mixing. Static or static mixers tend not to significantly decompose the foam or dispense foam gas into the foam.
Oakes混合機、Lessco混合機、またはHansa Frothing Unit等の任意の従来の装置を用いて、空気または他の気体をポリウレタン形成組成物またはそれらの一部分に泡立てることによって機械的に発泡させることにより発泡が行われる。そのような機械的に発泡させた混合物を調製する方法は、米国特許第4,853,054号、同第5,104,693号、同第5,908,701号、同第6,040,381号、同第6,096,401号、及び同第6,555,199号に記載されており、すべては参照により本明細書に組み込まれる。ポリウレタン形成組成物は、適用前に、約2500〜600、特に、275〜400グラム/リットルの泡密度まで発泡される。 Foaming is achieved by mechanical foaming by bubbling air or other gas into the polyurethane-forming composition or part thereof using any conventional apparatus such as an Oakes mixer, Lessco mixer, or Hansa Frothing Unit. Done. Methods for preparing such mechanically foamed mixtures are described in U.S. Pat. Nos. 4,853,054, 5,104,693, 5,908,701, 6,040, 381, 6,096,401, and 6,555,199, all of which are incorporated herein by reference. The polyurethane-forming composition is foamed to a foam density of about 2500-600, especially 275-400 grams / liter, prior to application.
次いで、結果として生じる発泡ポリウレタン形成組成物は、少なくとも24インチ(61cm)の幅を有する織物の表面をわたる層へと形成される。組成物の層を広げ、それを既定の厚さに標準寸法にすることは、織物が広い場合には、かなりの時間を要し得るため、広い幅の織物は、ポリウレタン形成組成物の反応性において有意な混入物質を課す。織物は、6メートルまたはそれ以上の幅があってもよく、床仕上げ用途における典型的な幅は、1〜3メートル、特に1〜2メートルであってもよい。例えば、数ある中でもポリマーフィルムまたはシート、カーペット(パイル糸カーペットを含む)、織布、紙シート、剛体材料、例えば、木材、べにや、金属箔もしくはシート、または複合材料等を含む、多種多様の材料が基板として機能し得る。 The resulting polyurethane foam-forming composition is then formed into a layer over the surface of the fabric having a width of at least 24 inches (61 cm). Widening the composition layer and making it a standard dimension to a predetermined thickness can take a considerable amount of time if the fabric is wide, so wide fabrics are reactive with the polyurethane-forming composition. Imposes significant contaminants in The fabric may have a width of 6 meters or more, and a typical width in floor finishing applications may be 1-3 meters, especially 1-2 meters. A wide variety of materials including, for example, polymer films or sheets, carpets (including pile carpets), woven fabrics, paper sheets, rigid materials such as wood, beni, metal foil or sheets, or composite materials, among others Can function as a substrate.
特に興味深い基板は、房状または製織カーペット材料、特に単一層を有するものか、またはパイル糸を固定及び結束するために適切なポリマー接着剤で予めコーティングされたものである。カーペットは、カーペット表面を作製するために仕上げ繊維がそれを通じて房付けまたは製織される複数の開口を画成する主要な裏打ち材を含む。主要な裏打ち材は、一般に、製織または不織スクリムの形態であり、いずれかの好都合な材料、例えばジュート、ポリプロピレン、ナイロン、ポリエステル、ポリアクリレート、綿、羊毛、または他の材料等から作製され得る。仕上げ繊維も、いずれかの好都合な材料、例えば羊毛、綿、ナイロン、ポリエステル、アクリル繊維、ポリプロピレン、ポリエチレン、これらのいずれか2つまたはそれ以上のブレンド等からなり得る。単一層は、好適には、ラテックス、ポリウレタン、またはホットメルトであるか、またはビチューメンまたはポリオレフィン等の1つ以上の他の複合層と組み合わせた単一の裏打ちである。仕上げ繊維は、典型的に、カーペット表面及び対向する下側を作製するために主要な裏打ち材を通じて房付けまたは製織される繊維束の形態である。仕上げ繊維はまた、糸の束が主な織物を通して房付けされない結合カーペットとして知られている構造において組み立てられ得るが、結合ポリマーと共に最小限に接着される。典型的には、結合カーペットは、本明細書に記述されるさらなる構造上の構成成分を有するであろう。 Particularly interesting substrates are tufted or woven carpet materials, in particular those having a single layer, or pre-coated with a suitable polymer adhesive for fixing and binding pile yarns. The carpet includes a primary backing that defines a plurality of openings through which finished fibers are tufted or woven to create a carpet surface. The primary backing material is generally in the form of a woven or non-woven scrim and may be made from any convenient material such as jute, polypropylene, nylon, polyester, polyacrylate, cotton, wool, or other materials. . The finished fiber can also be made of any convenient material such as wool, cotton, nylon, polyester, acrylic fiber, polypropylene, polyethylene, a blend of any two or more thereof, and the like. The single layer is preferably a single backing in combination with one or more other composite layers, such as latex, polyurethane, or hot melt, or bitumen or polyolefin. Finish fibers are typically in the form of fiber bundles that are tufted or woven through a primary backing to create the carpet surface and the opposing underside. The finish fibers can also be assembled in a structure known as bonded carpet where the yarn bundle is not tufted through the main fabric, but is minimally bonded with the bonded polymer. Typically, a bonded carpet will have additional structural components as described herein.
織物上に層を形成するステップは、ポリウレタン形成組成物が十分に配合され(水及び触媒の添加を含む)、発泡した後、及び水とポリイソシアネート基との反応により、ポリウレタン形成組成物の任意の有意な膨張前、できるだけ早く行われる。物理的膨張剤の沸点及び動作温度に応じて、層への泡の形成前または形成時に、物理的膨張剤の揮発により、発泡を開始して、多少膨張させてもよい。織物上の層に泡が形成された時に、泡密度は、好ましくは、少なくとも250グラム/リットルである。 The step of forming a layer on the woven fabric comprises any of the polyurethane forming compositions after the polyurethane forming composition is fully formulated (including addition of water and catalyst), foamed, and by reaction of water with polyisocyanate groups. It takes place as soon as possible before significant swelling. Depending on the boiling point of the physical expansion agent and the operating temperature, foaming may be initiated and expanded somewhat by volatilization of the physical expansion agent before or during the formation of the foam in the layer. When foam is formed in a layer on the fabric, the foam density is preferably at least 250 grams / liter.
様々な装置の種類が、ポリウレタン形成組成物を分与し、それを層に形成するのに適している。組成物を分与する好ましい方法は、基板を前後に移動して基板表面にわたって組成物を多かれ少なかれ均一に分与する、移動式分与ノズル、ホース、またはヘッドによってである。組成物は、組成物を所望の厚さに標準寸法にして、組成物を基板の表面へ押し進めるのに役立つドクターブレードの上流で適切に分与される。ポリウレタン形成組成物を層へと形成して、それを標準寸法にするための別の好適な装置は、エアナイフである。これらの方法において、織物は、ポリウレタン形成組成物を織物と接触させ、層へと形成して、標準寸法にする1つ以上のステーションを通って継続的に移動させることが好ましい。 Various device types are suitable for dispensing the polyurethane-forming composition and forming it into layers. A preferred method of dispensing the composition is by a mobile dispensing nozzle, hose, or head that moves the substrate back and forth to dispense the composition more or less uniformly across the substrate surface. The composition is suitably dispensed upstream of a doctor blade that helps standardize the composition to the desired thickness and push the composition to the surface of the substrate. Another suitable device for forming the polyurethane-forming composition into layers and making it a standard dimension is an air knife. In these methods, the fabric is preferably continuously moved through one or more stations where the polyurethane-forming composition is contacted with the fabric, formed into layers, and brought to standard dimensions.
ポリウレタン形成組成物がドクターブレードの上流に分与される場合、液だまりが形成される。分与速度及びライン速度は、有利には、300秒以下、好ましくは、200秒以下の液だまりにおける平均残留時間(すなわち、分与からブレードの下を通過するまでの時間)を提供するように選択される。 When the polyurethane-forming composition is dispensed upstream of the doctor blade, a puddle is formed. The dispensing speed and line speed are advantageously such that they provide an average residence time in the puddle of 300 seconds or less, preferably 200 seconds or less (ie, the time from dispensing to passing under the blade). Selected.
構成成分は、早期の反応を最小限に抑える、またはその反応を防ぐために、好ましくは、40℃以下、好ましくは、約0℃〜約30℃、特に、約18℃〜約24℃の温度で、混合され、発泡され、層へと形成される。 The component is preferably at a temperature of 40 ° C. or less, preferably from about 0 ° C. to about 30 ° C., in particular from about 18 ° C. to about 24 ° C. in order to minimize or prevent premature reaction. , Mixed, foamed and formed into layers.
発泡組成物は、約10〜約70オンス/立方ヤード(0.33〜2.31kg/m2)、特に、約15〜約30オンス/立方ヤード(0.49〜0.99kg/m2)のコーティング重量で適用されるのが好ましい。適用された層の厚さは、通常、約0.05〜約0.75インチ(0.13〜1.9cm)、好ましくは0.1〜0.6インチ(0.25〜1.5cm、及びより好ましくは約0.2〜約0.5インチ(0.52〜1.27cm)である。 The foamed composition is about 10 to about 70 ounces / cubic yard (0.33 to 2.31 kg / m 2 ), in particular about 15 to about 30 ounces / cubic yard (0.49 to 0.99 kg / m 2 ). It is preferably applied at a coating weight of The applied layer thickness is typically about 0.05 to about 0.75 inches (0.13 to 1.9 cm), preferably 0.1 to 0.6 inches (0.25 to 1.5 cm, And more preferably from about 0.2 to about 0.5 inches (0.52 to 1.27 cm).
次いで、発泡組成物が自由に上昇して、発泡ポリウレタンクッションを形成することができるように、発泡ポリウレタン形成組成物の層を、その上面が大気に開放された状態で硬化させる。硬化ステップ時、水がイソシアネート基と反応して、二酸化炭素を発生し、核を成し、気泡を形成し、発泡層をさらに膨張させる。物理的膨張剤はまた、硬化ステップ時に、連続して揮発させることができ、そのような場合には、このさらなる膨張にも起因するであろう。本発明の重要な特性は、適用された層のさらなる膨張が、基板上に形成された後に生じることである。適用された泡沫層の密度を176グラム/リットル以下に低下させることができるのが、このさらなる膨張である。膨張は、約64〜160g/L、及びより好ましくは96〜160g/L、特に、96〜136グラム/リットルの泡密度であることが望ましい。硬化された泡沫は、同じ範囲内の密度を有するべきである。 The layer of foamed polyurethane-forming composition is then cured with its top surface open to the atmosphere so that the foamed composition can rise freely to form a foamed polyurethane cushion. During the curing step, water reacts with isocyanate groups to generate carbon dioxide, nucleate, form bubbles and further expand the foam layer. The physical expansion agent can also be volatilized continuously during the curing step, in which case it may be due to this further expansion. An important property of the present invention is that further expansion of the applied layer occurs after being formed on the substrate. It is this further expansion that can reduce the density of the applied foam layer to 176 grams / liter or less. It is desirable for the expansion to be a foam density of about 64-160 g / L, and more preferably 96-160 g / L, especially 96-136 grams / liter. The cured foam should have a density within the same range.
米国特許第2007−0197674号に記載される方法とは対照的に、閉じ込め層は、ポリウレタン形成層には適用されない。その代わりに、ポリウレタン形成組成物の層の上部が大気に開放されて、それによって、それが硬化された後まで、ポリウレタン形成組成物に適用されるいかなる材料の層もない(すなわち、覆われていない)、またはそのような層が適用される場合、層は、大気へのポリウレタン形成組成物からのガスの漏出にいかなる有意な障害を提供しないことを意味する。例えば、目の荒いスクリムまたは他の材料は、硬化する場合に、ポリウレタン形成組成物の上に適用され得るが、但し、材料の開口がその表面積の50%以上、好ましくは80%以上を構成するものとする。開口を有するジュートまたはポリエステル裏打ちは、例えば、コーティングされた織物へのさらなる寸法安定性を与え、グルーダウン装置から織物の開放を促進する、または他の理由のために適用され得る。ポリウレタン形成組成物に適用される任意のそのような層は、組成物が膨張するのを妨げない十分に軽い重量でなければならず、好ましくは、任意のそのような層が125g/m2以下、好ましくは100g/m2以下の重さである。 In contrast to the method described in US 2007-0197674, no confinement layer is applied to the polyurethane forming layer. Instead, the top of the layer of polyurethane-forming composition is opened to the atmosphere so that there is no layer of any material applied to the polyurethane-forming composition until after it has been cured (i.e. covered). No), or when such a layer is applied, it means that the layer does not provide any significant obstacle to the escape of gas from the polyurethane-forming composition to the atmosphere. For example, an open scrim or other material can be applied over the polyurethane-forming composition when cured, provided that the material openings constitute 50% or more, preferably 80% or more of its surface area. Shall. A jute or polyester backing with openings can be applied, for example, to provide additional dimensional stability to the coated fabric, to facilitate the release of the fabric from the glue down device, or for other reasons. Any such layer applied to the polyurethane-forming composition must be of a sufficiently light weight that does not prevent the composition from expanding, and preferably any such layer is no greater than 125 g / m 2. The weight is preferably 100 g / m 2 or less.
硬化は、好ましくは、ポリウレタン形成組成物の層を高温に供することによって達成される。一般に、ポリウレタン組成物が、約30分以内、好ましくは約2〜約10分、特に約2.5〜約5分、非粘着状態になるまで硬化する硬化温度を選択することが望ましい。好ましい温度範囲は、80〜170℃、特に約100〜150℃であり、これらの範囲は、基板、閉じ込め層及び/中間層として豊富な材料の選択の使用を可能にするのに十分広範である。硬化は、高温の硬化温度で所望の滞留時間を提供する速度でオーブンを通してアセンブリを通過させることによって、適宜行われる。加熱したコンベヤーベルトは、硬化に必要とされる加熱を提供するために使用され得る。基板は、ポリウレタン形成組成物と接触させる前に、若干、例えば、70〜110℃またはそれ以上で加熱され得、そのため、これらの層は、組成物からの熱を取り出さないため、その硬化を引き延ばす、または防ぐ。 Curing is preferably accomplished by subjecting the layer of polyurethane-forming composition to elevated temperatures. In general, it is desirable to select a cure temperature at which the polyurethane composition cures within about 30 minutes, preferably from about 2 to about 10 minutes, particularly from about 2.5 to about 5 minutes, until it is non-tacky. The preferred temperature range is 80-170 ° C., especially about 100-150 ° C., and these ranges are wide enough to allow the use of a selection of abundant materials as substrates, confinement layers and / or intermediate layers. . Curing is suitably accomplished by passing the assembly through an oven at a rate that provides the desired residence time at the elevated curing temperature. A heated conveyor belt can be used to provide the heating required for curing. The substrate may be heated slightly, eg, at 70-110 ° C. or higher, before contacting the polyurethane-forming composition, so that these layers do not extract heat from the composition and thus prolong its cure. Or prevent.
したがって、上述されたゲル時間に加えて、本発明で用いるのに好ましいポリウレタン形成組成物は、130〜150℃の範囲内の高温に曝す場合、2〜10分以内、好ましくは2.5〜5分以内非粘着状態になるまで硬化する。 Thus, in addition to the gel times described above, preferred polyurethane-forming compositions for use in the present invention are within 2-10 minutes, preferably 2.5-5 when exposed to high temperatures in the range of 130-150 ° C. Cure until non-tacky within minutes.
ポリウレタンが十分に硬化された後に、製品は、有利には、(例えば、巻き付けること、またはアキュムレータデバイスにそれをカスケードすることによって)屈曲または湾曲される前に40℃以下、特に35℃以下に冷却される。冷却は、製品がカーペットタイルの場合のように、ダイカットされる、または独立モジュールとして機能することを目的とする場合に特に好ましい。 After the polyurethane is fully cured, the product is advantageously cooled to below 40 ° C., in particular below 35 ° C. before being bent or curved (eg by wrapping or cascading it on an accumulator device) Is done. Cooling is particularly preferred when the product is intended to be die-cut or function as a stand-alone module, as in the case of carpet tiles.
ポリイソシアネートには、少なくとも1つの有機ポリイソシアネートが含まれ、芳香族、脂環式、または脂肪族イソシアネートであり得る。好適なポリイソシアネートの例としては、m−フェニレンジイソシアネート、トルエン−2,4−ジイソシアネート、トルエン−2,6−ジイソシアネート、ヘキサメチレン−1,6−ジイソシアネート、テトラメチレン−1,4−ジイソシアネート、シクロヘキサン−1,4−ジイソシアネート、ヘキサヒドロトルエンジイソシアネート、ナフチレン−1,5−ジイソシアネート、メトキシフェニル−2,4−ジイソシアネート、ジフェニルメタン−4,4’−ジイソシアネート、4,4’−ビフェニレンジイソシアネート、3,3’−ジメトキシ−4,4’−ビフェニルジイソシアネート、3,3’−ジメチル−4−4’−ビフェニルジイソシアネート、3,3’−ジメチルジフェニルメタン−4,4’−ジイソシアネート、4,4’,4’’−トリフェニルメタントリイソシアネート、ポリメチレンポリフェニルイソシアネート(PMDI)、トルエン−2,4,6−トリイソシアネート、及び4,4’−ジメチルジフェニルメタン−2,2’,5,5’−テトライソシアネートが挙げられる。好ましいポリイソシアネートは、ジフェニルメタン−4,4’−ジイソシアネート、ジフェニルメタン−2,4’−ジイソシアネート、PMDI、トルエン−2,4−ジイソシアネート、トルエン−2−6−ジイソシアネート、またはこれらの混合物である。ジフェニルメタン−4,4’−ジイソシアネート、ジフェニルメタン−2,4’−ジイソシアネート、及びこれらの混合物は、概して、MDIと称され、すべて使用することができる。トルエン−2,4−ジイソシアネート、トルエン−2,6−ジイソシアネート、及びこれらの混合物は、概して、TDIと称され、すべて使用することができる。平均して約1.8〜約2.5のイソシアネート基/分子を有するポリイソシアネート化合物またはこれらの混合物は、特に、平均約1.9〜約2.3のイソシアネート基/分子を有するものが好ましい。化学量論的過剰量の、前述のポリイソシアネートのうちのいずれかを以下に記載されるもの等のイソシアネート反応化合物と反応させることによって作製されるプレポリマーも使用することができる。好適なプレポリマーは、米国特許第5,104,693号に記載されるソフトセグメントプレポリマー及び米国特許第6,372,810号に記載されるハードセグメントプレポリマーを含む。 The polyisocyanate includes at least one organic polyisocyanate and can be an aromatic, alicyclic, or aliphatic isocyanate. Examples of suitable polyisocyanates include m-phenylene diisocyanate, toluene-2,4-diisocyanate, toluene-2,6-diisocyanate, hexamethylene-1,6-diisocyanate, tetramethylene-1,4-diisocyanate, cyclohexane- 1,4-diisocyanate, hexahydrotoluene diisocyanate, naphthylene-1,5-diisocyanate, methoxyphenyl-2,4-diisocyanate, diphenylmethane-4,4′-diisocyanate, 4,4′-biphenylene diisocyanate, 3,3′- Dimethoxy-4,4′-biphenyl diisocyanate, 3,3′-dimethyl-4-4′-biphenyl diisocyanate, 3,3′-dimethyldiphenylmethane-4,4′-diisocyanate, 4,4 ′, '' -Triphenylmethane triisocyanate, polymethylene polyphenyl isocyanate (PMDI), toluene-2,4,6-triisocyanate, and 4,4'-dimethyldiphenylmethane-2,2 ', 5,5'-tetraisocyanate Is mentioned. Preferred polyisocyanates are diphenylmethane-4,4'-diisocyanate, diphenylmethane-2,4'-diisocyanate, PMDI, toluene-2,4-diisocyanate, toluene-2-6-diisocyanate, or mixtures thereof. Diphenylmethane-4,4'-diisocyanate, diphenylmethane-2,4'-diisocyanate, and mixtures thereof are generally referred to as MDI and can all be used. Toluene-2,4-diisocyanate, toluene-2,6-diisocyanate, and mixtures thereof are generally referred to as TDI and can all be used. Polyisocyanate compounds having an average of about 1.8 to about 2.5 isocyanate groups / molecules or mixtures thereof are particularly preferred having an average of about 1.9 to about 2.3 isocyanate groups / molecules. . Prepolymers made by reacting any of the foregoing polyisocyanates in a stoichiometric excess with an isocyanate-reactive compound such as those described below can also be used. Suitable prepolymers include soft segment prepolymers described in US Pat. No. 5,104,693 and hard segment prepolymers described in US Pat. No. 6,372,810.
使用されるポリイソシアネートの量は、適宜に、出発反応混合物において、約85〜約130、好ましくは約90〜125、特に約95〜115のイソシアネート指数、すなわち、NCO基対イソシアネート反応性基の比の100倍したものを提供するのに十分な量である。 The amount of polyisocyanate used is suitably from about 85 to about 130, preferably from about 90 to 125, in particular from about 95 to 115 in the starting reaction mixture, ie the ratio of NCO groups to isocyanate reactive groups. This is enough to provide 100 times that.
ポリウレタン形成組成物は、少なくとも400のヒドロキシル当量を有する少なくとも1つのポリオールを含む。ポリオールのヒドロキシル当量は、好ましくは、約500〜約3000、特に約500〜約1500である。ポリオールは、有利には、約1.8〜約4、特に約2〜約3のヒドロキシル基/分子の平均公称官能基数を有する。そのようなポリオールの混合物を使用することができる。好適なポリオールは、ポリエーテルポリオール及びポリエステルポリオールを含む。ポリエーテルポリオールが、一般に、より好ましい。特に好適なポリエーテルポリオールは、最大20重量%の末端ポリ(エチレンオキシド)ブロックを有していてもよいプロピレンオキシドのポリマー、プロピレンオキシド及び最大約15重量%のエチレンオキシドのランダムコポリマー、ポリ(テトラメチレンオキシド)ポリマー、及びポリ(ブチレンオキシド)ポリマーである。好適なポリエステルポリオールは、国際公開第WO04/096882号及び同第WO04/096883号に記載される種類のヒドロキシメチル基含有ポリエステルポリオールを含む。好ましいポリオールは、主に、第2級ヒドロキシル基を有し、少なくとも70%、80%、90%、または98%が第2級ヒドロキシル基である。第2級基は、第1級基よりも低速でポリイソシアネートと反応する傾向があり、組成物が混合、発泡、及び適用されるときに反応開始を遅延させるのにさらに役立つように選択され得る。 The polyurethane-forming composition comprises at least one polyol having a hydroxyl equivalent weight of at least 400. The hydroxyl equivalent weight of the polyol is preferably from about 500 to about 3000, especially from about 500 to about 1500. The polyol advantageously has an average nominal functionality of hydroxyl groups / molecule of from about 1.8 to about 4, in particular from about 2 to about 3. Mixtures of such polyols can be used. Suitable polyols include polyether polyols and polyester polyols. Polyether polyols are generally more preferred. Particularly suitable polyether polyols are polymers of propylene oxide which may have up to 20% by weight of terminal poly (ethylene oxide) blocks, random copolymers of propylene oxide and up to about 15% by weight of ethylene oxide, poly (tetramethylene oxide) ) Polymers, and poly (butylene oxide) polymers. Suitable polyester polyols include hydroxymethyl group-containing polyester polyols of the type described in WO 04/096882 and WO 04/096883. Preferred polyols have primarily secondary hydroxyl groups and at least 70%, 80%, 90%, or 98% are secondary hydroxyl groups. The secondary groups tend to react with the polyisocyanate at a slower rate than the primary groups and can be selected to further help delay the onset of reaction when the composition is mixed, foamed, and applied. .
ポリウレタン形成組成物はまた、少なくとも400のヒドロキシル当量を有するポリオール(複数可)100重量部当たり0.2〜2部の水も含む。好ましい量は、少なくとも400のヒドロキシル当量を有するポリオール100重量部当たり0.6〜2部の水、またはポリオール(複数可)100重量部当たり1〜1.8部の水である。 The polyurethane-forming composition also includes 0.2 to 2 parts water per 100 parts by weight polyol (s) having a hydroxyl equivalent weight of at least 400. Preferred amounts are 0.6 to 2 parts water per 100 parts by weight polyol having a hydroxyl equivalent weight of at least 400, or 1 to 1.8 parts water per 100 parts by weight polyol (s).
物理的膨張剤は、−30〜40℃の沸点(1大気圧で)を有する任意の化合物であり、硬化ステップの条件下で、ポリウレタン形成組成物の他の構成成分とは反応しない。好ましい沸点は、0〜40℃であり、より好ましい沸点は、10〜30℃である。物理的膨張剤は、例えば、炭化水素、フッ化炭素、ヒドロフルオロカーボン、ヒドロフルオロクロロカーボン、ジアルキルエーテル、または他の化合物であり得る。ゼロオゾン消耗ポテンシャル及び20未満の地球温暖化ポテンシャルを有するものが好ましい。その中で好適な物理的膨張剤は、1,1,1,3,3−ペンタフルオロプロパン及び1−クロロ−3,3,3−トリフルオロプロパンである。物理的膨張剤の量は、好適には、少なくとも400のヒドロキシル当量を有するポリオール(複数可)100重量部当たり3〜10重量部である。より好適な量は、少なくとも400のヒドロキシル当量を有するポリオール(複数可)100重量部当たり5〜8重量部である。 A physical swelling agent is any compound having a boiling point of -30 to 40 ° C (at 1 atmospheric pressure) and does not react with the other components of the polyurethane-forming composition under the conditions of the curing step. A preferable boiling point is 0 to 40 ° C, and a more preferable boiling point is 10 to 30 ° C. The physical expansion agent can be, for example, a hydrocarbon, fluorocarbon, hydrofluorocarbon, hydrofluorochlorocarbon, dialkyl ether, or other compound. Those having a zero ozone consumption potential and a global warming potential of less than 20 are preferred. Among them, preferred physical swelling agents are 1,1,1,3,3-pentafluoropropane and 1-chloro-3,3,3-trifluoropropane. The amount of physical swelling agent is preferably 3 to 10 parts by weight per 100 parts by weight of polyol (s) having a hydroxyl equivalent weight of at least 400. A more preferred amount is 5 to 8 parts by weight per 100 parts by weight of polyol (s) having a hydroxyl equivalent weight of at least 400.
鎖延長剤または架橋剤もまた、ポリウレタン形成組成物中に存在し得る。本発明の目的では、鎖延長剤は、2個のイソシアネート反応性基/分子及び約30〜150のイソシアネート反応性基当たりの当量を有する物質である。架橋剤は、本発明の目的では、3個以上のイソシアネート反応性基及び150以下のイソシアネート反応性基当たりの当量を有する化合物である。イソシアネート反応性基は、ヒドロキシル基、第1級アミン基、または第2級アミン基であり得る。ヒドロキシル基を有する鎖延長剤及び架橋剤は、ヒドロキシル基がより低速で反応して、したがってポリウレタン形成層を適用及び標準寸法にするためにより長い時間を与えるために好ましい。好適な鎖延長剤の例には、エチレングリコール、ジエチレングリコール、トリエチレングリコール、プロピレングリコール、ジプロピレングリコール、トリプロピレングリコール、1,4−ジメチロールシクロへキサン、ジエチルトルエンジアミン、1,4−ブタンジオール、1,6−ヘキサンジオール、1,3−プロパンジオール、アミン末端ポリエーテル、例えばHuntsman Chemical CompanyからのJeffamine D−400、アミノエチルピペラジン、2−メチルピペラジン、1,5−ジアミノ−3−メチル−ペンタン、イソホロンジアミン、エチレンジアミン、ヘキサンジアミン、ヒドラジン、ピペラジン、それらの混合物等が含まれる。配合物の反応性を低下させて、泡沫層を適用及び計量するための作業時間をさらに提供するために、アミン鎖延長剤は、遮断、カプセル化、またはそうでなければ反応性を低くすることができる。鎖延長剤は、有利には、すべてのイソシアネート反応性材料の組み合わせた重量の最大約30%、特に最大約20%を構成する。 Chain extenders or crosslinkers may also be present in the polyurethane-forming composition. For purposes of the present invention, a chain extender is a material having two isocyanate reactive groups / molecule and an equivalent weight per isocyanate reactive group of about 30-150. A cross-linking agent is a compound having an equivalent weight per isocyanate reactive group of 3 or more and 150 or less of isocyanate reactive groups for the purposes of the present invention. The isocyanate-reactive group can be a hydroxyl group, a primary amine group, or a secondary amine group. Chain extenders and crosslinkers with hydroxyl groups are preferred because the hydroxyl groups react slower and thus give longer time to apply and standardize the polyurethane-forming layer. Examples of suitable chain extenders include ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, 1,4-dimethylolcyclohexane, diethyltoluenediamine, 1,4-butanediol. 1,6-hexanediol, 1,3-propanediol, amine-terminated polyethers such as Jeffamine D-400 from Huntsman Chemical Company, aminoethylpiperazine, 2-methylpiperazine, 1,5-diamino-3-methyl- Pentane, isophoronediamine, ethylenediamine, hexanediamine, hydrazine, piperazine, mixtures thereof and the like are included. Amine chain extenders should be blocked, encapsulated, or otherwise made less reactive to reduce the reactivity of the formulation and further provide work time for applying and metering the foam layer. Can do. The chain extender advantageously comprises up to about 30%, in particular up to about 20% of the combined weight of all isocyanate-reactive materials.
ポリウレタン形成組成物はまた、1つ以上の触媒も含有し、ポリイソシアネートとイソシアネート反応性材料の反応を促進する。好適な触媒には、第3級アミン、有機金属化合物、またはそれらの混合物が含まれる。これらの特定の例には、ジ−n−ブチルスズビス(メルカプト酢酸イソオクチルエステル)、ジメチルスズジラウレート、ジブチルスズジラウレート、ジブチルスズジアセテート、ジブチルスズスルフィド、第一スズオクトアート、鉛オクトアート、ニッケルアセチルアセトネート、鉄アセチルアセトネート、ビスマスカルボキシレート、トリエチレンジアミン、N−メチルモルホリン、様化合物、及びそれらの混合物が含まれる。米国特許第5,491,174号に記載されるもの等のアミン遮断スズ(IV)触媒を使用することができる。特に好ましい触媒は、米国特許第5,646,195号に記載される、ジアルキルスズスルフィド触媒等の遅延作用触媒である。最新の種類のうちで、ジメチル−、ジブチル−、及びジオクチルスズスルフィド触媒が、特に興味深いものである。触媒は、遅延反応を得るために、ワックスまたは他の低融点材料中にカプセル化され得る。 The polyurethane-forming composition also contains one or more catalysts to promote the reaction between the polyisocyanate and the isocyanate-reactive material. Suitable catalysts include tertiary amines, organometallic compounds, or mixtures thereof. Specific examples of these include di-n-butyltin bis (mercaptoacetic acid isooctyl ester), dimethyltin dilaurate, dibutyltin dilaurate, dibutyltin diacetate, dibutyltin sulfide, stannous octoate, lead octoate, nickel acetylacetonate , Iron acetylacetonate, bismuth carboxylate, triethylenediamine, N-methylmorpholine, like compounds, and mixtures thereof. Amine-blocked tin (IV) catalysts such as those described in US Pat. No. 5,491,174 can be used. Particularly preferred catalysts are delayed action catalysts such as dialkyl tin sulfide catalysts described in US Pat. No. 5,646,195. Of the latest types, dimethyl-, dibutyl-, and dioctyltin sulfide catalysts are of particular interest. The catalyst can be encapsulated in wax or other low melting material to obtain a delayed reaction.
触媒の量は、有利には、ポリウレタン形成組成物が少なくとも180秒のゲル時間を有するように使用される。ゲル時間は、すべての構成成分を20℃にし、その温度でそれらを混合し、構成成分の反応によって発生した熱により、49℃の温度を得るために反応混合物に対して必要とされる時間を測定することによって、適宜に測定される。好ましい組成物は、180〜600秒、特に180〜約300秒のゲル時間を有する。 The amount of catalyst is advantageously used so that the polyurethane-forming composition has a gel time of at least 180 seconds. The gel time is the time required for the reaction mixture to bring all components to 20 ° C., mix them at that temperature, and the temperature generated by the reaction of the components to obtain a temperature of 49 ° C. By measuring, it measures appropriately. Preferred compositions have a gel time of 180 to 600 seconds, especially 180 to about 300 seconds.
有機金属触媒が使用される場合、そのような硬化は、ポリウレタン形成組成物の100重量部当たり約0.01〜約0.5重量部であり得る。第3アミン級触媒が使用される場合、触媒は、好ましくは、ポリウレタン形成組成物の100重量部当たり約0.01〜約3重量部の第3級アミン触媒を提供する。組成物は、有利には、少なくとも30秒、好ましくは30〜90秒のクリーム時間を示す。クリーム時間は、すべての材料が混合されると、ポリウレタン形成組成物が膨張し始めるのに必要とされる時間である。 When an organometallic catalyst is used, such curing can be from about 0.01 to about 0.5 parts by weight per 100 parts by weight of the polyurethane-forming composition. When a tertiary amine class catalyst is used, the catalyst preferably provides from about 0.01 to about 3 parts by weight of a tertiary amine catalyst per 100 parts by weight of the polyurethane-forming composition. The composition advantageously exhibits a cream time of at least 30 seconds, preferably 30-90 seconds. Cream time is the time required for the polyurethane-forming composition to begin to swell once all ingredients are mixed.
ポリウレタン形成組成物は、全費用を削減して、難燃性、硬度、及び他の物理的特性を改善し得る充填剤を含有する。充填剤の量は、少なくとも400のヒドロキシル当量を有するポリオール(複数可)100重量部当たり100〜400重量部、好ましくは、同じ基準にして200〜400重量部、より好ましくは250〜350重量部である。好適な充填剤には、タルク、雲母、モンモリロナイト、大理石、硫酸バリウム(バライト)、花こう岩、粉砕ガラス、炭酸カルシウム、アルミニウムトリハイドレート、炭素、アラミド、シリカ、シリカ−アルミナ、ジルコニア、タルク、ベントナイト、アンチモントリオキシド、カオリン、石炭ベースフライアッシュ、及びボロンニトリドが含まれる。 Polyurethane-forming compositions contain fillers that can reduce overall costs and improve flame retardancy, hardness, and other physical properties. The amount of filler is from 100 to 400 parts by weight per 100 parts by weight of polyol (s) having a hydroxyl equivalent weight of at least 400, preferably from 200 to 400 parts by weight, more preferably from 250 to 350 parts by weight on the same basis. is there. Suitable fillers include talc, mica, montmorillonite, marble, barium sulfate (barite), granite, ground glass, calcium carbonate, aluminum trihydrate, carbon, aramid, silica, silica-alumina, zirconia, talc, Bentonite, antimony trioxide, kaolin, coal-based fly ash, and boron nitride are included.
ポリウレタン形成組成物はまた、組成物が硬化されるまで気泡を安定化させる役割を果たす少なくとも1つの泡沫安定化界面活性剤も含む。米国特許第4,483,894号に記載されるもの等のオルガノシリコーン界面活性剤が好ましい。典型的には、少なくとも400のヒドロキシル当量を有するポリオール(複数可)100重量部当たり約0.5〜約3部の界面活性剤が、使用される。 The polyurethane-forming composition also includes at least one foam stabilizing surfactant that serves to stabilize the cells until the composition is cured. Organosilicone surfactants such as those described in US Pat. No. 4,483,894 are preferred. Typically, about 0.5 to about 3 parts of surfactant are used per 100 parts by weight of polyol (s) having a hydroxyl equivalent weight of at least 400.
難燃剤、顔料、静電気防止剤、補強繊維、酸化防止剤、保存料、酸掃去剤等を含む、他の添加物が使用され得る。 Other additives may be used including flame retardants, pigments, antistatic agents, reinforcing fibers, antioxidants, preservatives, acid scavengers and the like.
この方法からなる製品が、基板の織物の片側に取り付けられたポリウレタンクッションである。織物の全幅は、コーティングプロセス及び硬化プロセス時、織物を保持または輸送するいくつかの器具によって握られるか、またはそうでなければ、保持される対向する端に沿った限界地域を(任意に)除いて、取り付けられたクッションで覆われていることが好ましい。この製品は、例えば、広幅カーペット、カーペットタイル、下敷きまたは他のクッション性のある製品、遊び場表面、体育館の床または体操用マット等のマット、人工芝生等であり得る。 A product consisting of this method is a polyurethane cushion attached to one side of the substrate fabric. The overall width of the fabric is gripped by some device that holds or transports the fabric during the coating and curing processes, or (optionally) excludes marginal areas along the opposite edges where it is held. And preferably covered with an attached cushion. This product can be, for example, wide carpets, carpet tiles, underlays or other cushioning products, playground surfaces, mats such as gym floors or gymnastic mats, artificial lawns, and the like.
次の実施例は本発明を例証するが、その範囲を制限することは意図されない。すべての部及びパーセンテージは、別途明記されない限り、重量による。別途明記されない限り、本明細書で示すすべての分子量は、数平均分子量である。 The following examples illustrate the invention but are not intended to limit its scope. All parts and percentages are by weight unless otherwise specified. Unless otherwise specified, all molecular weights indicated herein are number average molecular weights.
実施例1及び2ならびに比較サンプルA及びB
実施例1:ポリオール混合物を、87% プロピレンオキシド及び13% エチレンオキシドの3000分子量の公称3官能性ランダムコポリマー48.3部、プロピレンオキシド及びエチレンオキシドの4800分子量の公称3官能性ブロックコポリマー40部、プロピレンオキシド及びエチレンオキシドの2000分子量の公称2官能性ブロックコポリマー10部、ジエチレングリコール4部、ヒマシ油1部、シリコーン泡沫安定化界面活性剤1.2部、粘度抑制剤1部、ポリエーテルポリオール中1% ジブチルスズスルフィド溶液2部、及び水1.8部から形成する。このポリオール混合物を、ブレンドが120°F(49℃)の温度に達するまで炭酸カルシウム粒子190部とブレンドする。得られた充填ポリオール混合物を約20℃まで冷却する。
Examples 1 and 2 and comparative samples A and B
Example 1: A polyol mixture was prepared from 48.3 parts of a 3000 molecular weight nominal trifunctional random copolymer of 87% propylene oxide and 13% ethylene oxide, 40 parts of a nominal trifunctional block copolymer of 4800 molecular weight of propylene oxide and ethylene oxide, propylene oxide. And ethylene oxide nominal bifunctional block copolymer of 2000 molecular weight, 4 parts diethylene glycol, 1 part castor oil, 1.2 parts silicone foam stabilizing surfactant, 1 part viscosity inhibitor, 1% dibutyltin sulfide in polyether polyol Form from 2 parts of solution and 1.8 parts of water. This polyol mixture is blended with 190 parts of calcium carbonate particles until the blend reaches a temperature of 120 ° F. (49 ° C.). The resulting filled polyol mixture is cooled to about 20 ° C.
充填ポリオールを、2インチ(5.08cm)のOakes分与/発泡機械に装填する。別々に、ポリマーMDI(イソシアネート指数90)43部、及びHFC−245fa(1,1,1−3,3−ペンタフルオロプロパン)6部を、Oakes機械に装填し、それらを充填ポリオール混合物と組み合わせ、得られた反応混合物を、泡密度が301g/Lになるまで発泡させる。存在する泡の温度は、31℃である。 The charged polyol is loaded into a 2 inch (5.08 cm) Oakes dispensing / foaming machine. Separately, 43 parts of polymer MDI (isocyanate index 90) and 6 parts HFC-245fa (1,1,1-3,3-pentafluoropropane) are charged to an Oakes machine and combined with the filled polyol mixture, The resulting reaction mixture is foamed until the foam density is 301 g / L. The temperature of the foam present is 31 ° C.
Oakes機械から放出された泡の一部を容器中に捕捉し、反応物の発熱が49℃の温度に上昇するまで、その温度を測定する。この温度に達するのに必要とされる時間(すなわち、ゲル化時間)は、6分5秒である。 A portion of the foam released from the Oakes machine is trapped in the container and the temperature is measured until the reaction exotherm rises to a temperature of 49 ° C. The time required to reach this temperature (ie gel time) is 6 minutes 5 seconds.
泡の別の一部を非粘着裏打ち材上に放出し、約7/16インチ〜5/8インチ(1.1〜1.58cm)の厚さに計量し、次いで140℃のオーブン中で覆わずに硬化した。硬化した材料を非粘着裏打ち材から取り外す。試験サンプルを調製し、密度25% IFD及び65% IFDが測定され、表1にあるような結果を有する。二重の試験サンプルを、ASTM D 5252に従ってHexapodタンブルドラムテスターにおいて20,000サイクルで処理し、25% IFD及び65% IFDが測定される。元のサンプルと比較して、IFDの損失は、表1に報告された通りである。IFDの増加は、負の損失として報告されている。 Another portion of the foam is discharged onto a non-stick backing, weighed to a thickness of about 7/16 inch to 5/8 inch (1.1 to 1.58 cm) and then covered in an oven at 140 ° C. Without curing. Remove the cured material from the non-stick backing. Test samples were prepared and densities of 25% IFD and 65% IFD were measured and have the results as in Table 1. Duplicate test samples are processed at 20,000 cycles in a Hexapod tumble drum tester according to ASTM D 5252 and 25% IFD and 65% IFD are measured. Compared to the original sample, the loss of IFD is as reported in Table 1. The increase in IFD is reported as a negative loss.
比較サンプルAは、第一に、水の量が2.3重量部まで増加する、これらの違いがあるが、同じ一般的な方法において作製される。触媒の量を、2.3部まで増加させ、増加した水の量に適応させる。HFC−245faは省略する。組成物の粘度は、物理的膨張剤を省略する結果としてより高くなるため、炭酸カルシウム粒子の量は、190部から170部のみに軽減される。 Comparative sample A is made in the same general manner, with the difference being that, firstly, the amount of water is increased to 2.3 parts by weight. The amount of catalyst is increased to 2.3 parts to accommodate the increased amount of water. HFC-245fa is omitted. Since the viscosity of the composition is higher as a result of omitting the physical swelling agent, the amount of calcium carbonate particles is reduced from 190 parts to only 170 parts.
比較サンプルCは、触媒の量を1.4部に軽減し、炭酸カルシウム粒子の量が180部であることを除いて、比較サンプルAと同じ様式で作製される。 Comparative sample C is made in the same manner as comparative sample A except that the amount of catalyst is reduced to 1.4 parts and the amount of calcium carbonate particles is 180 parts.
実施例2は、イソシアネート指数を100まで増加することを除いて、実施例1と同じ様式で作製される。 Example 2 is made in the same manner as Example 1 except that the isocyanate index is increased to 100.
比較サンプルA及びBならびに実施例2のそれぞれについては、発泡材のゲル化時間及び密度25% IFD及び65 IFDは、これまでと同じように測定される。結果は、表1にある通りである。 For each of Comparative Samples A and B and Example 2, the foam gel time and density 25% IFD and 65 IFD are measured as before. The results are as shown in Table 1.
実施例1及び比較サンプルAは、直接比較である。物理的膨張剤を追加の水と置き換え、それに対応して、触媒レベルを増加させることにより、ゲル化時間がはるかに短い系が得られる。比較サンプルAにおける泡密度は、実施例1よりも著しく高い。これは、比較サンプルAが発泡をより困難にするより高い粘度を有することを示す。閉じ込め層を用いずに、比較サンプルAの材料は、183g/Lの(または実施例1よりも約15%高い)硬化密度をもたらす。物理的膨張剤を一部の水と置き換える場合(実施例1等の場合)、閉じ込め層がないにもかかわらず、より低い密度が得られる。 Example 1 and comparative sample A are direct comparisons. By replacing the physical swelling agent with additional water and correspondingly increasing the catalyst level, a system with a much shorter gel time is obtained. The foam density in comparative sample A is significantly higher than in Example 1. This indicates that Comparative Sample A has a higher viscosity that makes foaming more difficult. Without the confinement layer, the material of Comparative Sample A provides a cure density of 183 g / L (or about 15% higher than Example 1). If the physical swelling agent is replaced with some water (such as in Example 1), a lower density is obtained despite the lack of a confinement layer.
比較サンプルBにおいて、触媒レベル及び硬化温度を、それぞれ、低減させて、より低速に硬化する系を得るように試みる(不成功に終わった)。これにより、硬化生成物においてさらに高い密度をもたらす。 In comparative sample B, the catalyst level and curing temperature are each reduced to attempt to obtain a system that cures more slowly (successfully). This results in a higher density in the cured product.
実施例2は、イソシアネート指数を100まで増加させる効果を示す。実施例1よりも若干高い密度が得られるが、密度は、依然として、比較サンプルの密度よりもはるかに下回っている。 Example 2 shows the effect of increasing the isocyanate index to 100. Although a slightly higher density is obtained than in Example 1, the density is still much lower than that of the comparative sample.
25% ILD値は、実施例1及び2の硬化したクッションが比較サンプルA及びBよりもはるかに柔軟であり、これはクッション性のある製品において望ましい。 The 25% ILD value is that the cured cushions of Examples 1 and 2 are much more flexible than Comparative Samples A and B, which is desirable in cushioned products.
25% ILDの損失値及び65% ILDの損失値は、実施例1及び2の材料が、比較サンプルよりもはるかに耐久性があることを示した。負の値は、耐久性試験後の増加を示す。それに対して、比較サンプルは、この試験において耐荷重性における非常に重大な損失、特に、25%の圧入を示す。 The loss values of 25% ILD and 65% ILD indicated that the materials of Examples 1 and 2 were much more durable than the comparative samples. Negative values indicate an increase after the durability test. In contrast, the comparative sample shows a very significant loss in load bearing capacity, in particular 25% indentation, in this test.
Claims (10)
a)1リットル当たり約250〜600グラムの密度を有する発泡ポリウレタン形成組成物であって、前記ポリウレタン形成組成物が、少なくとも400のヒドロキシル当量を有する少なくとも1つのポリオールを含む1つ以上のポリオール、少なくとも400のヒドロキシル当量を有するポリオール(複数可)100重量部当たり0.25〜2部の水、少なくとも400のヒドロキシル当量を有するポリオール(複数可)100重量部当たり3〜10重量部の、−30〜40℃の沸点を有する物理的膨張剤、少なくとも400のヒドロキシル当量を有するポリオール(複数可)100重量部当たり100〜400重量部の充填剤、泡沫安定化界面活性剤、85〜130のイソシアネート指数を提供するのに十分な量の少なくとも1つのポリイソシアネート、及び前記ポリウレタン形成組成物が少なくとも180秒のゲル化時間を有するような量のポリウレタン触媒を含む、発泡ポリウレタン形成組成物を形成することと、
b)少なくとも24インチ(61cm)の幅を有する織物の上面をわたる0.05〜0.75インチ(0.127〜1.9cm)の厚さの層へと未硬化の泡を形成することと、
c)前記発泡組成物が自由に上昇して、前記織物に結合された176グラム/リットル(11ポンド/立方フィート)以下の密度を有する発泡ポリウレタンクッションを形成することができるように、前記発泡組成物の層を、その上面が大気に開放された状態で硬化させることと、を含む、前記方法。 A method for making a fabric lined with a cushion,
a) a foamed polyurethane-forming composition having a density of about 250-600 grams per liter, wherein the polyurethane-forming composition comprises at least one polyol having a hydroxyl equivalent weight of at least 400, at least 0.25-2 parts water per 100 parts by weight of polyol (s) having a hydroxyl equivalent of 400, 3-10 parts by weight per 100 parts by weight of polyol (s) having a hydroxyl equivalent of 400, -30 A physical swelling agent having a boiling point of 40 ° C., 100 to 400 parts by weight of filler, 100 parts by weight of a polyol (s) having a hydroxyl equivalent weight of at least 400, a foam stabilizing surfactant, an isocyanate index of 85 to 130 An amount of at least one poly sufficient to provide And the isocyanate, and the polyurethane-forming composition comprises an amount of polyurethane catalyst such as those having a gelling time of at least 180 seconds, to form a polyurethane foam forming composition,
b) forming uncured foam into a 0.05 to 0.75 inch (0.127 to 1.9 cm) thick layer over the top surface of the fabric having a width of at least 24 inches (61 cm); ,
c) The foam composition so that the foam composition is free to rise to form a foam polyurethane cushion having a density of 176 grams / liter (11 pounds / cubic foot) or less bonded to the fabric. Curing the layer of material with its top surface open to the atmosphere.
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CN108368228A (en) * | 2015-12-16 | 2018-08-03 | 株式会社普利司通 | Flexible polyurethane foams and seat cushion |
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